EP2884179A1 - System for transporting solids with improved solids packing - Google Patents
System for transporting solids with improved solids packing Download PDFInfo
- Publication number
- EP2884179A1 EP2884179A1 EP14197289.3A EP14197289A EP2884179A1 EP 2884179 A1 EP2884179 A1 EP 2884179A1 EP 14197289 A EP14197289 A EP 14197289A EP 2884179 A1 EP2884179 A1 EP 2884179A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- solids
- solid feed
- assisting
- tap
- inlet
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23K—FEEDING FUEL TO COMBUSTION APPARATUS
- F23K1/00—Preparation of lump or pulverulent fuel in readiness for delivery to combustion apparatus
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
- B01F23/60—Mixing solids with solids
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F31/00—Mixers with shaking, oscillating, or vibrating mechanisms
- B01F31/60—Mixers with shaking, oscillating, or vibrating mechanisms with a vibrating receptacle
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
- B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
- B01F35/71—Feed mechanisms
- B01F35/717—Feed mechanisms characterised by the means for feeding the components to the mixer
- B01F35/7176—Feed mechanisms characterised by the means for feeding the components to the mixer using pumps
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C4/00—Crushing or disintegrating by roller mills
- B02C4/28—Details
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07B—SEPARATING SOLIDS FROM SOLIDS BY SIEVING, SCREENING, SIFTING OR BY USING GAS CURRENTS; SEPARATING BY OTHER DRY METHODS APPLICABLE TO BULK MATERIAL, e.g. LOOSE ARTICLES FIT TO BE HANDLED LIKE BULK MATERIAL
- B07B1/00—Sieving, screening, sifting, or sorting solid materials using networks, gratings, grids, or the like
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07B—SEPARATING SOLIDS FROM SOLIDS BY SIEVING, SCREENING, SIFTING OR BY USING GAS CURRENTS; SEPARATING BY OTHER DRY METHODS APPLICABLE TO BULK MATERIAL, e.g. LOOSE ARTICLES FIT TO BE HANDLED LIKE BULK MATERIAL
- B07B11/00—Arrangement of accessories in apparatus for separating solids from solids using gas currents
- B07B11/06—Feeding or discharging arrangements
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G5/00—Incineration of waste; Incinerator constructions; Details, accessories or control therefor
- F23G5/008—Incineration of waste; Incinerator constructions; Details, accessories or control therefor adapted for burning two or more kinds, e.g. liquid and solid, of waste being fed through separate inlets
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23K—FEEDING FUEL TO COMBUSTION APPARATUS
- F23K3/00—Feeding or distributing of lump or pulverulent fuel to combustion apparatus
- F23K3/02—Pneumatic feeding arrangements, i.e. by air blast
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G2201/00—Pretreatment
- F23G2201/70—Blending
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G2205/00—Waste feed arrangements
- F23G2205/20—Waste feed arrangements using airblast or pneumatic feeding
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
- F23G2209/00—Specific waste
- F23G2209/26—Biowaste
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23K—FEEDING FUEL TO COMBUSTION APPARATUS
- F23K2201/00—Pretreatment of solid fuel
- F23K2201/50—Blending
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23K—FEEDING FUEL TO COMBUSTION APPARATUS
- F23K2900/00—Special features of, or arrangements for fuel supplies
- F23K2900/05004—Mixing two or more fluid fuels
Definitions
- the subject matter disclosed herein relates to pressurizing solids pumps.
- Various industrial processes include conveying solids from one process to another. Each process may use solids of various sizes, shapes, material consistencies, or other material characteristics. Additionally, each process may use the solids under various temperatures, pressures, humidity levels, or other operational conditions. As a result of different material characteristics and/or operational conditions between processes, it may be difficult to convey the solids from one process to the next.
- a system in a first embodiment, includes a solid feed pump that has a housing, a rotor disposed in the housing, a curved passage disposed between the rotor and the housing, a solid feed inlet coupled to the curved passage, and a solid feed outlet coupled to the curved passage.
- the system also includes a solids packing device coupled to the solid feed inlet of the solid feed pump.
- the solids packing device includes a first channel configured to receive a solid feed with a first range of sizes, a second channel configured to receive transport assisting particles (TAP) with a second range of sizes. The first range of sizes is different from the second range of sizes.
- a third channel is configured to receive and mix the solid feed and the TAP to provide a solid feed-TAP mixture with the TAP filling interspatial spaces between the solid feed.
- the third channel is coupled to the solid feed inlet.
- a system in a second embodiment, includes a solids packing device having a first inlet and a second inlet, a solids source configured to provide solids to the first inlet, and an assisting solids source configured to provide assisting solids to the second inlet.
- the solids have a first range of sizes and the assisting solids have a second range of sizes that is different from the first range of sizes.
- the system also includes a solids pump configured to receive the solids and the assisting solids from the solids packing device at a first pressure and deliver the solids and the assisting solids to a pressurized end user system at a second pressure.
- a system in a third embodiment, includes a solids packing device that has a first inlet and a second inlet, a first source configured to provide solids to the first inlet of the solids packing device, a second source configured to provide assisting solids to the second inlet of the solids packing device, a solids pump configured to receive the solids and the assisting solids from the solids packing device, and a solids separating device configured to receive the solids and the assisting solids from the solids pump, separate the solids from the assisting solids, and output the solids separate from the assisting solids.
- the present disclosure is related to systems for pumping a solid feed from a lower pressure section to a higher pressure section, or from higher pressure to lower pressure.
- the system may utilize a solids pump that has a channel that packs the solid feed with transport assisting solids that block any backflow from the higher pressure section to the lower pressure section.
- the transport assisting solids may include smaller sized particles of the same material as the solid feed, or the transport assisting solids may be different than the solid feed.
- the transport assisting solids may be fed into the packing channel through a dedicated channel.
- the assisting solids and the accompanying assisting solids channel enable the system to maintain a pressure differential for solid feeds that would otherwise allow significant leakage from the higher pressure section to the lower pressure section.
- FIG. 1 is a cross-sectional side view of an embodiment of a solids pump 10 (e.g., rotary disk type solids pressurizing feeder) that may be used in the systems described below.
- the rotary disk type solids pressurizing pump 10 may be a Posimetric® Feeder made by General Electric Company of Schenectady, New York.
- the rotary disk type solids pressurizing pump 10 includes a pressure housing (or body) 12, an inlet channel 14 (e.g., a converging inlet channel), an outlet channel 16 (e.g., a diverging outlet channel), and a rotor 18.
- the rotor 18 may include two substantially opposed and parallel rotary disks 20 separated by a hub 22 and joined to a shaft 24 that is common to the parallel disks 20 and the hub 22. As illustrated, the two disks 20 are not in the plane of the page, as are the rest of the elements in the figure. One of the disks 20 is below the plane of the page, and the other disk 20 is above the plane. The disk 20 below the plane of the page is projected onto the plane of the page in order that it may be seen in relation to the rest of the components comprising the disk type solids pressurizing pump 10.
- the outer, convex surface 28 of the hub 22, the annularly shaped portion of the two disks 20 that extend between the outer surface of the hub 22 and the peripheral edge 30 of the disks 20, and the inner, concave surface 32 of the feeder housing 12 define an annularly shaped, channel 33 (e.g., curved passage) that connects the converging inlet channel 14 and the diverging outlet channel 16.
- a portion 34 of the feeder body 12 that is disposed between the inlet channel 14 and the outlet channel 16 divides the channel 33 in such a way that solids entering the inlet channel 14 may travel only in the direction of rotation 26 of the rotor or shaft 24, so that the solids may be carried from the inlet channel 14 to the outlet channel 16 by the rotating annularly shaped channel 33 defined by the rotating outer surface of the hub 22, the rotating exposed annular surfaces of the disks 20, and the stationary inner surface 32 of the body 12.
- the particles progressively compact.
- the compaction may reach a point where the particles become interlocked and form a bridge across the entire cross-section of the channel 33.
- the length of the zone containing particles which have formed an interlocking bridge across the entire cross-section of the rotating channel 33 may become long enough that the force required to dislodge the bridged particulates from the channel 33 exceeds the force that can be generated by a high pressure environment at the outlet of the pump 10.
- lockup This condition, where the interlocking solids within the channel 33 cannot be dislodged by the high pressure at the outlet of the pump 10, is referred to as "lockup.”
- the torque delivered by the shaft 24 from a drive motor 25 may be transferred to the rotating solids so that the solids are driven from the inlet channel 14 to the outlet channel 16 against pressure in the high-pressure environment beyond the exit of the outlet channel 16.
- the rotor disks 20 may have raised or depressed surface features 36 formed onto their surfaces. These features may enhance the ability of the particulate solids to achieve lockup in the channel 33 and, therefore, may also enhance the ability of the drive shaft 24 to transfer torque to the rotating solids.
- the forces that held them in the lockup condition begin to relax to the point where, at the downstream exit of the outlet channel 16, the particles are gradually able to freely disengage from the outlet channel 16 and proceed downstream.
- the solids may be subjected to the upstream force of the constantly advancing solids that are locked up and being driven forward by the rotor 18 and the downstream force of the high-pressure environment into which the solids are being transported.
- the solids in an upstream portion 17 (e.g., inlet) of the outlet channel 16 may compact even further and may form a dynamic, packed bed (e.g., a dynamic seal) that is highly resistant to the backflow of fluids (e.g., gases or liquids) from the high-pressure environment at the discharge of the pump 10. It is this zone of highly packed, flow resistant particulate solids that may block any significant backflow of fluids (e.g., process gases or liquids) from the outlet channel 16 (e.g., high pressure outlet) to the inlet channel 14 (e.g., low pressure inlet) of the pump 10.
- fluids e.g., gases or liquids
- This highly packed, flow resistant zone of solids may form an imperfect seal, and some fluid may leak backwards through the tightly packed solids at the upstream inlet 17 of the outlet channel 16.
- the amount of backflow may be small, and the small amount of fluid that may work its way through the tightly packed solids may be released through a vent 38 and, thus, blocked from flowing backwards all the way through the channel 33 to the inlet channel 14.
- the small amount of fluid (gases or liquids) that may be collected in the vent 38 may either be disposed of or recycled to an appropriate location elsewhere in the process.
- the rotary disk type solids pressurizing pump 10 may function to separate two processes having differing pressures and/or differing chemical compositions.
- the rotating disk type solids pressurizing pump 10 operates as a solids depressurizing feeder, e.g., in a "depressurizing mode."
- the solid particulates from a high-pressure zone enter the channel 16 (e.g., functioning as an inlet channel rather than an outlet channel.
- Depressurizing feeders may also employ shapes that are different than for the inlets/outlets as well as the channel.
- the inlets for the depressurizing feeder may have larger or smaller channels.
- the depressurizing feeders may be the same feeders as the pressurizing feeders, simply running in reverse. Or the depressurizing feeders may be specifically designed for depressurization.
- the solids As the solids progress downwards through the channel 16, the solids move through the dynamic, highly compacted zone at the bottom of the channel 16 that forms the highly back flow resistant zone that prevents unwanted backflow from the high-pressure region at the outlet channel 16 to the low-pressure region at the channel 14.
- the annularly shaped channel 33 continues to rotate in the reversed direction 27, the solids are carried back to the channel 14 where the locking forces that held them in place inside the rotating channel relax and allow the solids to disengage from one another as they exit the inlet channel 14 on the low pressure side of the pump 10.
- a lower pressure reactor vessel is coupled together with a higher pressure reactor vessel, and at least one solids pressurizing feeder 16 operating in pressurizing mode and one solids pressurizing pump 10 operating in depressurizing mode may be used to transport solids between the vessels and/or other equipment.
- one, two, or more solids pressurizing feeders 10 may both operate in the pressurizing mode.
- FIG. 2 shows the solids pump 10 illustrated in FIG. 1 with the inlet channel 14, solids transport channel 33 (i.e., the channel defined by the convex surface 28 and the concave surface 32), and outlet channel 16 transporting a solids flow 40 of a finely divided transport assisting solids 41 (e.g., sand, ground biomass, coal fines, petroleum coke fines, pulverized limestone, ground glass, small flexible polymer beads, crumb rubber, and the like or any combination thereof).
- the transport assisting solids 41 are solids that have been pulverized, ground, crushed, manufactured, formed and/or treated in some way so that each particle is defined by a particle diameter 42.
- the particle diameter 42 may be defined by a maximum value for each particle or the transport assisting solids 41 may be defined by a certain proportion being smaller than a maximum value.
- the transport assisting solids 41 may all be smaller than approximately 30-50 Mesh (i.e., 0.599-0.297 ⁇ m).
- the transport assisting solids 41 may include material in which 60, 70, 80, or 90 percent of the particles are smaller than approximately 100 Mesh (i.e., 0.152 ⁇ m).
- the small diameter (relative to the size of the channel 33) particles illustrated in FIG. 2 represent the various particles and depict that the particles 40 are capable of forming a tightly packed column within the pump 10 that is capable of sustaining the high pressure drop between the high pressure zone at the outlet channel 16 and the low pressure zone at the inlet channel 14.
- FIG. 3 is a schematic of a simplified representation of an embodiment of a section 46 of the curved solids transport channel 33 between the inlet channel 14 and the outlet channel 16 of the solids pump 10 shown in FIGS. 1 and 2 , illustrating a solids flow 40 of relatively fine particulate solids 41 moving through the pump 10.
- the solids flow 40 e.g., low pressure fire particulate solids 41
- moves through the channel 33 in a downstream direction 26 e.g., from left to right
- the fine particulate solids 41 are relatively closely packed together to help block fluid flow, such as gas or liquid flow.
- the fine particulate solids 41 with tight packing can resist a gas flow 44 (e.g., high pressure gas flow 44) flowing in an upstream direction 27 (e.g., from right to left), from the high pressure zone at the outlet channel 16 to the low pressure zone at the inlet channel 14.
- the finely ground solids 40 have a particle size 42 distribution that is conducive to forming tightly packed solids in the pump 10, such as in the channel 33 and the outlet channel 16.
- the distribution of the particle size 42 may include a broad range of particle sizes in order to achieve tight packing, or the particle size 42 in some embodiments may have a narrow size distribution.
- the particle size 42 of the solids 41 may be relatively small. In these cases, open space or voids between the solids 41 is limited in size.
- the high pressure gas 44 Due to the small spaces between the solids 40, the high pressure gas 44 has a difficult time flowing from right to left. That is, pathways 52 for gas flow 44 from the outlet channel 16 to the inlet channel 14 are few and small. Therefore, a high pressure drop is sustained between the outlet channel 16 and the inlet channel 14.
- FIG. 4 is a schematic of the section 46 of the curved solids transport channel 33 filled with large solid particles 48 (e.g., coarse particulate solids), which may have a narrow particle size 50 distribution (i.e., relative to the tightly packed fine solids 41 in FIG. 3 ).
- a narrow size distribution means that for example, due to the limited range of particle sizes (there are no small particles to fill in the gaps), or the random and irregular shapes of the particles, the particles do a poor job of packing and the resulting poorly packed solids offer little resistance to gas flow from outlet channel 16 to inlet channel 14.
- Pathways i.e., spaces, voids, or gaps 52
- FIG. 5 is a schematic of the section 46 of the curved solids transport channel 33 of FIGS. 3 and 4 , illustrating transport of a solids mixture of the large solid particles 48 (e.g., of FIG. 4 ) and the finely ground solids 41 (e.g., of FIGS. 2 and 3 ).
- the small, tightly-packing solids 41 are able to fill all the spaces between the large solids particle 48. Therefore, the pathways 52 for gas flow 44 are few and small.
- the tight packing of the solids flow 40 achieved by the fine particulate solids 41 enables the pump 10 to maintain a high pressure drop between the outlet channel 16 and the inlet channel 14.
- both the small particles (e.g., transport assisting solids 41) and the large particles (e.g., solid feed 48) can be transported by the pump 10 against a high pressure gas 44.
- the assisting solids 41 may be made from a broad range of suitable materials.
- a solids packing device 64 may use an attrition resistant material that is different from the solid feed 48 material. These materials are used in transport assisting solids recycle embodiments as explained in detail below.
- the assisting solids 41 may also include the same material as the solid feed 48. That is, a portion of the solid feed 48 may be pulverized to obtain a particle size distribution that is more efficient at packing the solids flow 40.
- the assisting solids 41 may also be made from polymer or rubber balls or beads that are flexible, resilient and compressible and that can deform around and cushion the large solids (particularly fragile chunk solids) as they pass through the solids pump 10.
- the assisting solids 41 may also be made from a material (e.g. fluxant, additive, reactant) that is a desired participant in the downstream processing of the chunk solids 48. Either all or just a portion of these types of transport assisting solids 41 stay with the pressurized chunks 48 that are fed into the end user process.
- FIG. 6 shows a block flow diagram for one embodiment of a system that employs the concept illustrated in FIG. 5 .
- Solids 48 from a source of oversize solids 54 pass through a solids sizing device 56, such as a grinder or crusher, in order to produce size-reduced solids 48 which are sized small enough to pass through the solids pump 10.
- the source of oversize solids 54 may be a hopper or bin that stores the solids 48, or may be a conveyor that constantly conveys the solids 48 to the solids sizing device 56.
- the source of oversize solids 54 may also have other structural components. If the oversized solids 48 are already small enough to pass through the pump 10, the size reduction step may be eliminated.
- the size-reduced solids 48 are stored in a sized chunk solids bin 58 for further use.
- sized chunks, chunks and chunk solids refer to solids that are characterized by a narrow particle size distribution with relative little or no smaller size particles available to fill in the gaps 52 between the larger ones (e.g., the solids 48 shown in FIG. 4 ).
- solids 41 e.g., relatively fine particulate solids 41
- transport assisting solids bin 62 are loaded into a transport assisting solids bin 62 for further use.
- These solids 41 are capable of forming a tightly packed column, because they include a wide range of particle sizes 42, including fine and very fine particles that are able to fill in essentially all of the gaps 52 between all larger particles 48.
- chunk solids 48 and transport assisting solids 41 are combined or mixed in a solids packing device 64.
- the solids packing device 64 may be located immediately upstream of the inlet channel 14 and is configured to completely surround the solid feed 48 with the finer transport assisting solids 41 so that all of the gaps 52 between the solid feed 48 that would otherwise be left open are now filled with transport assisting solids 41.
- the combination 66 (e.g., solids mixture 43) of chunk 48 and transport assisting solids 41 then enters the solids pump 10 that meters and pressurizes the combination 66 into an end user process 68 such as a gasifier, a reactor, a furnace, a boiler, a combustor, a high pressure treating process, or any combination thereof.
- an end user process 68 such as a gasifier, a reactor, a furnace, a boiler, a combustor, a high pressure treating process, or any combination thereof.
- FIG. 7 is a schematic of an embodiment of the solids packing device 64 of FIG. 6 .
- a top portion 70 of the device 64 includes two concentric solids delivery nozzles 72, 74.
- the center nozzle 72 introduces the sized solid feed 48 into a central portion of the solids packing device 64
- the outer nozzle 74 introduces the transport assisting solids 41 into the device 64 around the outside of the solid feed 48.
- Both nozzles i.e., center nozzle 72 and outer nozzle 74
- the center nozzle 72 may be either flush with or retracted from the exit orifice 75 of the outer nozzle 74. As illustrated, the center nozzle 72 is retracted (e.g., axially offset) from an exit orifice 75 of the outer nozzle 74.
- a middle portion 78 of the solids packing device 64 includes a vibrating packing column that ensures that the solid feed 48 and the transport assisting solids 41 are well mixed and well packed (e.g., a column 77 ensures that all the gaps 52 between the solid feed 48 are completely filled with the transport assisting solids 41).
- Both the external vibrator 76 and one or more internal vibrators 80 disposed within a flow path of the solids 48 and transport assisting solids 41 are provided to ensure that thorough mixing and packing of the two solids 41, 48 streams occurs.
- Other embodiments may include only one vibrator (76 or 80), and still other embodiments may include no vibrators, or additional vibrators within and external to the device 64.
- a bottom portion 82 of the solids packing device 64 includes a live wall column 81 that actively transports the packed solids mixture 66 into the inlet channel 14 of the solids pump 10 attached immediately below an exit 84 of the device 64.
- the live wall column 81 of the bottom portion 82 has a rotating channel 83 with internal spiral flutes 86 that act as a screw conveyor that actively moves the mixed solids stream 66 (e.g., solids mixture 43) downwards through the channel 83.
- the rotating channel 83 is driven by a gear, such as an external worm gear 87.
- the solid feed 48 may include a material that is somewhat fragile. Fragile materials 48 may be damaged by the solids pump 10, because of the high compressive and frictional forces that develop within portions of the pump 10.
- the transport assisting solids 41 may include small, flexible polymer or rubber beads.
- the beads 41 that are added to the device 64 include shapes and a particle size distribution that facilitates efficient packing with the solid feed 48 being fed through the device 64.
- the solids packing device 64 mixes the flexible, compressible beads 41 with the large, fragile solid feed 48, the solid feed 48 are surrounded by the beads 41 and all the gaps 52 (e.g., void spaces) in the combination 66 are filled with the beads 41.
- the flexible, compressible beads 41 not only provide the tight packing to sustain a pressure drop across the pump 10, but the beads 41 also cushion the fragile solid feed 48, thereby reducing the possibility that the chuck solids 48 may be damaged during their passage through the solids pump 10.
- FIG. 8 is a schematic of an embodiment of an equipment configuration for the process embodiment shown in FIG. 6 .
- a source of oversize solids 54 passes the solids 48 (e.g., coal, petroleum coke, limestone, ore, wood, biomass, carbon-containing waste materials or any combination thereof) through a grinder 56 that reduces the solids to chunks that can effectively pass through the solids pump 10 (e.g., without jamming).
- the grinder 56 may be any suitable grinder that produces solids with the desired particle size.
- the grinder 56 may also size a portion of the oversize solids 54 into transport assisting solids 60.
- the solid feed 48 e.g., coal
- the solid feed 48 is then stored in a sized chunk solids bin or hopper 58.
- a source of transport assisting solids 60 such as pulverized coal 41 (e.g., possibly prepared from the same source), is loaded into the transport assisting solids bin or hopper 62.
- the transport assisting solids bin or hopper 62 may be of any suitable construction that is compatible with the transport assisting solids 41 which it stores for use within the solids packing device 64.
- the bin or hopper 62 may also be a conveyor belt, tube, or pump that constantly conveys the solids 41 to the solids packing device 64.
- the source of oversize solids 54 may also have other structural components.
- the bottoms of both the transport assisting solids bin 62 and the sized chunk solids bin 58 may be fitted with rotating star valves 88 or other similar devices that meter the two solids 41, 48 into the solids packing device 64.
- the two star valves 88 may be controlled by a controller so as to feed the assisting solids 41 and the solid feed 48 into the solids packing device 64 at a ratio that achieves efficient packing.
- the solids packing device 64 mixes and packs the two solids (i.e., solid feed 48, such as chunk coal, and assisting solids 41, such as pulverized coal) together and then feeds the combination 66 into the inlet channel 14 of the solids pump 10.
- the solids pump 10 simultaneously pressurizes and meters the combination 66 of pulverized and chunk coal 43 into a downstream end user process 68 (e.g. a pressurized fluidized bed combustor, reactor, or gasifier).
- pulverized coal that was used as the transport assisting solids in the first example.
- limestone may be used as a sulfur sorbent in coal combustion applications, and the use of pulverized limestone as the transport assisting solids 41 in the equipment configuration of FIG. 8 provides a convenient way to co-feed coal and sulfur sorbent into a pressurized fluidized bed combustor, reactor, or gasifier.
- the source of solid feed 48 may be wood, wood waste or some other oversize biomass material; and the transport assisting solids 41 may be sawdust or similar finely divided biomass from a biomass processing facility.
- the solids packing device 64 mixes and packs the sized wood or biomass chunks 48 with the sawdust or finely divided biomass 41 and then feeds the combined biomass stream 43, 66 to the solids pump 10.
- the solids pump 10 in turn, pressurizes and meters the combined biomass stream 43 into the downstream end user process 68, such as a fluidized bed biomass gasifier or a steam-biomass reformer.
- a biomass feeding process may significantly improve the efficiency and economics of many biomass conversion processes.
- biomass conversion processes are currently limited to relatively low pressure operation, because of the difficulty of pressurizing biomass feedstocks, many of which are available in sizes and particle size distributions that do not pack well.
- most biomass conversion processes must compress the product bio-syngas downstream of the biomass reactor in order to obtain high enough pressure for further processing, such as converting the bio-syngas to biomass-derived liquid fuels and chemicals or combusting the bio-syngas in a combustion turbine to generate electrical power.
- the biomass reactor can be operated at pressure that is higher than the pressures used by all downstream processes and, therefore, the intermediate compressor can be eliminated.
- one or more pieces of equipment may be added, substituted or subtracted within the scope of the embodiment in the block flow diagram of FIG. 6 .
- the grinder 56 may be eliminated.
- the solids pump 10 is shown as discharging directly into the end user process 68, the solids pump 10 may discharge to a screw conveyor, a pneumatic conveying system, or another process or device that does the final feeding to the end user process 68.
- FIG. 9 illustrates an embodiment for delivering the combination 66 of solid feed 48 and assisting solids 41 to the end user process 68.
- the transport assisting solids bin 62, the solids sizing device 56, the sized chunk solids bin 58, the solids packing device 64 and the solids pump 10 generally have the same features and functions as described in the block flow diagram of FIG. 6 .
- the embodiment of FIG. 9 is configured for situations in which the transport assisting solids 41 are not used by the end user process 68 along with the pressurized chunk solids.
- a solids separating device 90 may be placed downstream of the solids pump 10 to separate the transport assisting solids 41 from the solid feed 48 before the solid feed 48 is delivered to the end user process 68 by a pressurized solids delivery system 92.
- the transport assisting solids 41 that were separated by the solids separating device 90 are recycled back to the front end of the process in a recycle loop that begins with a transport assisting solids depressurizing device 94.
- the solids 41 are sent through a transport assisting solids attrited fines removal 96 where at least some of the attrited fines 97 are removed in order to prevent very fine material from accumulating within the transport assisted solids recycle loop.
- the non-attrited fines fraction of the transport assisting solids 41 is then moved via a recycle system 98 to a transport assisting solids recycle bin 100 that provides buffer storage in the recycle system.
- Recycled transfer assisting solids 41 are mixed with fresh transfer assisting solids and stored in a transport assisting solids 41 mixing and storage bin 102 upstream of the solids packing device 64.
- Mixed transport assisting solids 41 from the mixing and storage bin 102 are metered into the solids packing device 64 along with the sized solid feed 48 to complete the cycle.
- FIG. 10 illustrates a cross-section of an embodiment of the solids separating device 90 that can be used for the solids separation step downstream of the solids pump 10.
- a first example 104 is a simple, pressurized vibrating screen 106 with openings 108 that are small enough to block the solid feed 48 from passing through but large enough to allow the transport assisting solids 41 to pass.
- the separating device 90 may also include a tapered collection portion 109 that aggregates the transport assisting solids 41. Aggregation by the tapered collection portion 109 of the transport assisting solids 41 may reduce losses that would otherwise result from the fine particulates in the transport assisting solids 41 floating away due to agitation.
- FIG. 11 illustrates a cross-section of an embodiment of the solids separating device 90.
- the solids separating device 90 of FIG. 11 is a rotating cylindrical tumbler screen 110 inside a cylindrical pressure housing 112 that collects the separated transport assisting solids 41.
- the packed solids combination 66 from the discharge of the solids pump 10 is fed into the rotating screen 110, which is oriented with a slight downward slope from inlet 113 to outlet 114.
- internal baffles 115 tumble the solids (e.g., the combination 66, solid feed 48, and/or assisting solids 41).
- the transport assisting solids 41 pass through small holes 116 in the screen 110, while the larger solid feed 48 are retained inside the screen 110 and, after progressing along the length of the downwardly sloping rotating screen 110, leave the solids separation device via exit 114 to the end user process 68.
- FIG. 12 illustrates a cross-section of an embodiment of the solids separating device 90.
- the solids separating device 90 of FIG. 12 includes a vertical rotating screw conveyor 118 inside a tubular screen 120 fixed inside a pressurized cylindrical barrel 122 that collects the separated transport assisting solids 41.
- the packed solids combination 66 exits from the solids pump outlet channel 16 toward the angled inlet that intersects one side of the top of the tubular screen 120 and the solids (e.g., the combination 66, solid feed 48, and/or assisting solids 41) are transported downwards by the rotation of the screw 118.
- FIGS. 10, 11, and 12 illustrate three possible examples of solids separation devices 90, the disclosed systems and methods may use any other solids separating devices 90 alone or in combination with any or all of the devices 90 depicted in FIGS. 10, 11, and 12 .
- FIG. 13 illustrates an embodiment for the process shown in FIG. 9 .
- a source 54 of oversize solid feed 48 such as wood or oversize biomass, is reduced, if needed, to a size that will not get stuck in the solids pump 10.
- the sized solid feed 48 is stored in a sized chunk solids bin or hopper 58 with a rotating star valve 88 or similar device at the bottom that meters the solid feed 48 into the solids packing device 64.
- Mixed transport assisting solids 41 from the transport assisting solids mixing and solids bin 102 are also metered into the solids packing device 64 via a rotating star valve 88 or similar device at the bottom of that bin 102.
- the rotating star valves 88 are controlled in such a way as to meter the sized solid feed 48 and the assisting solids 41 into the solids packing device 64 in the correct mass flow ratio.
- the solids packing device 64 mixes and packs the solid feed 48 with the assisting solids 41 and feeds the combination 66 (e.g., solids mixture 43) to the inlet channel 14 of a solids pump 10.
- the solids pump 10 pressurizes the mixed and packed combination 66 to the pressure used within the end user process 68.
- the illustrated embodiment in FIG. 13 may be used when the end user process 68 does not accept the assisting solids 41 that were pressurized along with the solid feed 48. Therefore, a separating device 90, such as one or more of the embodiments shown in FIGS. 10-12 , is deployed downstream of the solids pump 10.
- the vertical rotating screw conveyor 118 may be used to separate the assisting solids 41 from the solid feed 48. Also as illustrated, the process of separation by the separating device 90 may occur completely within the pressurized zone 120 (e.g., the section of the in which processes are at a higher pressure than the sections outside the pressurized zone 120). As the pressurized combination 66 from the solids pump 10 passes through the vertical rotating screw conveyor 118, the assisting solids 41 pass through the screen and are collected in the outer barrel while the solid feed 48 is delivered by the screw to the inlet of a second solids pump 10 which may perform the final metering of the solid feed 48 into the end user process 68.
- the pressurized zone 120 e.g., the section of the in which processes are at a higher pressure than the sections outside the pressurized zone 120.
- the second solids pump 10 has a high pressure body, but it does little or no additional pressurization of the solid feed 48. Therefore, the second solids pump 10 may be the same type of solids pump, or may be a different type of solids pump 10. The second solids pump 10 may also be configured as just a metering device.
- the assisting solids 41 which were separated from the solid feed 48 enter a third solids pump 10 which operates in depressurization mode to reduce the pressure of the assisting solids 41 back to atmospheric pressure or another low pressure.
- the third solids pump 10 may also be the same type as either the first or the second solids pump 10, or the third solids pump 10 may be different than either of the other solids pumps 10.
- the depressurized assisting solids 41 are then screened in the transport assisting solids attrited fines removal unit 96 to remove the very finest attrited particles 97 of the assisting solids 41.
- the overflow from the attrited fines removal unit 96 is transported via a recycle system 98 such as a conveyor belt, a screw conveyor or a pneumatic conveying system to an assisting solids recycle storage bin or hopper 100.
- Fresh assisting solids 41 are also loaded into a fresh assisting solids storage bin or hopper 62.
- Both of these bins or hoppers e.g., fresh assisting solids storage bin 62 and assisting solids recycle storage bin 100
- the assisting solids mixing column 104 contains an open structure of internal baffles that mixes the two assisting solids 41 streams at the ratio of mass flow rates controlled by the star valves 88 as the two streams fall by gravity through the baffle structure within the mixing column 104 and into the transport assisting solids mixing and storage bin 102.
- One or more of the illustrated pieces of equipment may be added, substituted, or subtracted within the scope of the embodiment shown in the block flow diagram of FIG. 9 .
- the grinder 56 may be eliminated.
- the second solids pump 10 is shown as discharging directly into the downstream end user process 68, the second pump 10 may alternatively discharge to a screw conveyor, a pneumatic conveying system, a chute or another process or device that does the final feeding to the end user process 68.
- the second solids pump may be replaced by a screw conveyor, a pneumatic conveying system, a chute or another device that does the final feeding directly from the discharge of the solids separator 90 into the end user process 68.
- the vertical screw conveyor screen separating device 118 may be replaced or supplemented with one of the other solids separating devices 90
- the third solids pump 10 may be replaced by a lock hopper system
- the attrited fines screen 96 and the transport assisting solids mixing column 104 may be replaced by alternative devices that perform the same or similar functions.
- FIG. 13 may also be used to represent a possible equipment configuration for a third process embodiment that is also consistent with the block flow diagram shown in FIG. 9 .
- the first process embodiment, shown in FIG. 8 may be a once-through system in which the transport assisting solids 41 pass through the system just once and then are fed into the downstream end user process 68 along with the sized chunk solids 48. Such a process may be useful when the transport assisting solids can be tolerated by the end user process or when they can be fashioned from a material that is a desired participant in the further processing of the sized chunk solids 48 in the end user process 68.
- the third process embodiment which may also be represented by the equipment in FIG. 13 , is a hybrid of the first and second embodiments.
- a difference is that the efficiency of the solids separating device 90 downstream of the solids pump 10 is reduced so that some of the transport assisting solids 41 are separated for recycle while the rest remain with the sized chunk solids and are fed into the downstream end user process 68.
- Such a process may be useful when the transport assisting solids can be fashioned from a material that is a desired participant in the further processing of the sized chunk solids 48 in the end user process, but not in the quantity that is required to achieve the desired level of packing to sustain the pressure drop across the solids pump 10.
- An example might be a high pressure metals refining process in which a small amount of non-metallic fluxant is desirable.
- the efficiency of the solids separating device 90 can be tailored to allow just enough of it to pass through with the chunk solids 48 so that any fluxant used by the downstream end user process 68 is sufficiently provided.
- the system also includes a solids packing device coupled to the solid feed pump.
- the solids packing device receives chunk solids 48 with a narrow range of chunk sizes, and also receives transport assisting particles 41 with a second range of sizes.
- the first range of sizes may be bigger than the second range of sizes, but the first range of sizes does not allow the chunk solids to pack tightly enough to maintain the pressure differential between the high pressure condition and the low pressure condition.
- An additional channel is configured to receive and mix the solid feed 48 and the transport assisting particles 41 to provide a solid feed 48/transport assisting particles 41 mixture with the transport assisting particles 41 filling interspatial spaces 52 between the solid feed 48.
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Abstract
Description
- The subject matter disclosed herein relates to pressurizing solids pumps.
- Various industrial processes include conveying solids from one process to another. Each process may use solids of various sizes, shapes, material consistencies, or other material characteristics. Additionally, each process may use the solids under various temperatures, pressures, humidity levels, or other operational conditions. As a result of different material characteristics and/or operational conditions between processes, it may be difficult to convey the solids from one process to the next.
- Certain embodiments commensurate in scope with the originally claimed invention are summarized below. These embodiments are not intended to limit the scope of the claimed invention, but rather these embodiments are intended only to provide a brief summary of possible forms of the invention. Indeed, the invention may encompass a variety of forms that may be similar to or different from the embodiments set forth below.
- In a first embodiment, a system includes a solid feed pump that has a housing, a rotor disposed in the housing, a curved passage disposed between the rotor and the housing, a solid feed inlet coupled to the curved passage, and a solid feed outlet coupled to the curved passage. The system also includes a solids packing device coupled to the solid feed inlet of the solid feed pump. The solids packing device includes a first channel configured to receive a solid feed with a first range of sizes, a second channel configured to receive transport assisting particles (TAP) with a second range of sizes. The first range of sizes is different from the second range of sizes. A third channel is configured to receive and mix the solid feed and the TAP to provide a solid feed-TAP mixture with the TAP filling interspatial spaces between the solid feed. The third channel is coupled to the solid feed inlet.
- In a second embodiment, a system includes a solids packing device having a first inlet and a second inlet, a solids source configured to provide solids to the first inlet, and an assisting solids source configured to provide assisting solids to the second inlet. The solids have a first range of sizes and the assisting solids have a second range of sizes that is different from the first range of sizes. The system also includes a solids pump configured to receive the solids and the assisting solids from the solids packing device at a first pressure and deliver the solids and the assisting solids to a pressurized end user system at a second pressure.
- In a third embodiment, a system includes a solids packing device that has a first inlet and a second inlet, a first source configured to provide solids to the first inlet of the solids packing device, a second source configured to provide assisting solids to the second inlet of the solids packing device, a solids pump configured to receive the solids and the assisting solids from the solids packing device, and a solids separating device configured to receive the solids and the assisting solids from the solids pump, separate the solids from the assisting solids, and output the solids separate from the assisting solids.
- These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
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FIG. 1 is a cross-sectional side view of an embodiment of a solids pump that may be used in the systems described below; -
FIG. 2 illustrates the solids pump ofFIG. 1 with an inlet channel, a solids transport channel, and an outlet channel filled with finely ground solids; -
FIG. 3 illustrates a simplified schematic of an embodiment of the solids transport channel filled with the finely ground solids between the inlet channel and the outlet channel of the solids pump shown inFIGS. 1 and2 taken along line 3-3; -
FIG. 4 is a simplified schematic of an embodiment of the solids transport channel of -
FIG. 3 filled with large solid particles; -
FIG. 5 is a simplified schematic of an embodiment of the solids transport channel ofFIG. 3 filled with the large solid particles and the finely ground solids ofFIGS. 3 and 4 ; -
FIG. 6 is a block diagram of an embodiment of a system that prepares a solids mixture and pumps the solids mixture with the solids pump ofFIGS. 1-5 ; -
FIG. 7 is a schematic of an embodiment of a solids packing device that prepares the solids mixture for the system ofFIG. 6 ; -
FIG. 8 is a schematic of an embodiment of an equipment configuration of the system shown inFIG. 6 ; -
FIG. 9 is a block diagram of an embodiment of a system for mixing, pumping, and separating fine and coarse particulate solids; -
FIGS. 10-12 are schematics of embodiments of a solids separating device that can be used for separating solids downstream of the solids pump in the system ofFIG. 9 ; and -
FIG. 13 is a schematic diagram of an embodiment of the system shown inFIG. 9 . - One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
- When introducing elements of various embodiments of the present invention, the articles "a," "an," "the," and "said" are intended to mean that there are one or more of the elements. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements.
- The present disclosure is related to systems for pumping a solid feed from a lower pressure section to a higher pressure section, or from higher pressure to lower pressure. The system may utilize a solids pump that has a channel that packs the solid feed with transport assisting solids that block any backflow from the higher pressure section to the lower pressure section. The transport assisting solids may include smaller sized particles of the same material as the solid feed, or the transport assisting solids may be different than the solid feed. The transport assisting solids may be fed into the packing channel through a dedicated channel. The assisting solids and the accompanying assisting solids channel enable the system to maintain a pressure differential for solid feeds that would otherwise allow significant leakage from the higher pressure section to the lower pressure section.
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FIG. 1 is a cross-sectional side view of an embodiment of a solids pump 10 (e.g., rotary disk type solids pressurizing feeder) that may be used in the systems described below. The rotary disk typesolids pressurizing pump 10 may be a Posimetric® Feeder made by General Electric Company of Schenectady, New York. As illustrated, the rotary disk typesolids pressurizing pump 10 includes a pressure housing (or body) 12, an inlet channel 14 (e.g., a converging inlet channel), an outlet channel 16 (e.g., a diverging outlet channel), and arotor 18. Therotor 18 may include two substantially opposed and parallelrotary disks 20 separated by ahub 22 and joined to ashaft 24 that is common to theparallel disks 20 and thehub 22. As illustrated, the twodisks 20 are not in the plane of the page, as are the rest of the elements in the figure. One of thedisks 20 is below the plane of the page, and theother disk 20 is above the plane. Thedisk 20 below the plane of the page is projected onto the plane of the page in order that it may be seen in relation to the rest of the components comprising the disk typesolids pressurizing pump 10. The outer,convex surface 28 of thehub 22, the annularly shaped portion of the twodisks 20 that extend between the outer surface of thehub 22 and theperipheral edge 30 of thedisks 20, and the inner,concave surface 32 of thefeeder housing 12 define an annularly shaped, channel 33 (e.g., curved passage) that connects the converginginlet channel 14 and the divergingoutlet channel 16. Aportion 34 of thefeeder body 12 that is disposed between theinlet channel 14 and theoutlet channel 16 divides thechannel 33 in such a way that solids entering theinlet channel 14 may travel only in the direction ofrotation 26 of the rotor orshaft 24, so that the solids may be carried from theinlet channel 14 to theoutlet channel 16 by the rotating annularlyshaped channel 33 defined by the rotating outer surface of thehub 22, the rotating exposed annular surfaces of thedisks 20, and the stationaryinner surface 32 of thebody 12. - As solids enter and move downwards through the converging
inlet channel 14, the particles progressively compact. As the particles continue to be drawn downwards and into therotating channel 33, the compaction may reach a point where the particles become interlocked and form a bridge across the entire cross-section of thechannel 33. As the compacted particles continue to move through the rotatingchannel 33 in the direction ofrotation 26, the length of the zone containing particles which have formed an interlocking bridge across the entire cross-section of the rotatingchannel 33 may become long enough that the force required to dislodge the bridged particulates from thechannel 33 exceeds the force that can be generated by a high pressure environment at the outlet of thepump 10. This condition, where the interlocking solids within thechannel 33 cannot be dislodged by the high pressure at the outlet of thepump 10, is referred to as "lockup." By achieving the condition of lockup, the torque delivered by theshaft 24 from adrive motor 25 may be transferred to the rotating solids so that the solids are driven from theinlet channel 14 to theoutlet channel 16 against pressure in the high-pressure environment beyond the exit of theoutlet channel 16. In some embodiments, therotor disks 20 may have raised or depressed surface features 36 formed onto their surfaces. These features may enhance the ability of the particulate solids to achieve lockup in thechannel 33 and, therefore, may also enhance the ability of thedrive shaft 24 to transfer torque to the rotating solids. - As the particles move through the diverging
outlet channel 16, the forces that held them in the lockup condition begin to relax to the point where, at the downstream exit of theoutlet channel 16, the particles are gradually able to freely disengage from theoutlet channel 16 and proceed downstream. However, at the divergingoutlet channel 16, the solids may be subjected to the upstream force of the constantly advancing solids that are locked up and being driven forward by therotor 18 and the downstream force of the high-pressure environment into which the solids are being transported. Under these compressive forces, from both upstream and downstream, the solids in an upstream portion 17 (e.g., inlet) of theoutlet channel 16 may compact even further and may form a dynamic, packed bed (e.g., a dynamic seal) that is highly resistant to the backflow of fluids (e.g., gases or liquids) from the high-pressure environment at the discharge of thepump 10. It is this zone of highly packed, flow resistant particulate solids that may block any significant backflow of fluids (e.g., process gases or liquids) from the outlet channel 16 (e.g., high pressure outlet) to the inlet channel 14 (e.g., low pressure inlet) of thepump 10. This highly packed, flow resistant zone of solids may form an imperfect seal, and some fluid may leak backwards through the tightly packed solids at theupstream inlet 17 of theoutlet channel 16. However, the amount of backflow may be small, and the small amount of fluid that may work its way through the tightly packed solids may be released through avent 38 and, thus, blocked from flowing backwards all the way through thechannel 33 to theinlet channel 14. The small amount of fluid (gases or liquids) that may be collected in thevent 38 may either be disposed of or recycled to an appropriate location elsewhere in the process. As a result of the dynamic packed bed at theinlet 17 of theoutlet channel 16 that is highly resistive to fluid backflow, and by venting the small amount of fluid which may work its way back through the dynamic packed bed of solids, the rotary disk typesolids pressurizing pump 10 may function to separate two processes having differing pressures and/or differing chemical compositions. - The operation of the rotary disk type
solids pressurizing pump 10 shown inFIG. 1 was explained above for an embodiment in which the rotation of the annularly shapedchannel 33 was from theinlet channel 14, which is at lower pressure, to theoutlet channel 16, which is at higher pressure. This mode of operation of thepump 10 may be referred to as a "pressurizing mode." However, the rotation of thedisks 20, and hence of the annularly shapedchannel 33, may be reversed so that the direction ofrotation 27 runs from the higher-pressure outlet channel 16 to the lowerpressure inlet channel 14. In this reversed direction ofrotation 27, the rotating disk typesolids pressurizing pump 10 operates as a solids depressurizing feeder, e.g., in a "depressurizing mode." When operating in the depressurizing mode, the solid particulates from a high-pressure zone enter the channel 16 (e.g., functioning as an inlet channel rather than an outlet channel. Depressurizing feeders may also employ shapes that are different than for the inlets/outlets as well as the channel. For example, the inlets for the depressurizing feeder may have larger or smaller channels. In other words, the depressurizing feeders may be the same feeders as the pressurizing feeders, simply running in reverse. Or the depressurizing feeders may be specifically designed for depressurization. - As the solids progress downwards through the
channel 16, the solids move through the dynamic, highly compacted zone at the bottom of thechannel 16 that forms the highly back flow resistant zone that prevents unwanted backflow from the high-pressure region at theoutlet channel 16 to the low-pressure region at thechannel 14. As the annularly shapedchannel 33 continues to rotate in the reverseddirection 27, the solids are carried back to thechannel 14 where the locking forces that held them in place inside the rotating channel relax and allow the solids to disengage from one another as they exit theinlet channel 14 on the low pressure side of thepump 10. In certain embodiments, a lower pressure reactor vessel is coupled together with a higher pressure reactor vessel, and at least onesolids pressurizing feeder 16 operating in pressurizing mode and onesolids pressurizing pump 10 operating in depressurizing mode may be used to transport solids between the vessels and/or other equipment. In embodiments with two vessels operating at essentially the same pressure, one, two, or moresolids pressurizing feeders 10 may both operate in the pressurizing mode. -
FIG. 2 shows the solids pump 10 illustrated inFIG. 1 with theinlet channel 14, solids transport channel 33 (i.e., the channel defined by theconvex surface 28 and the concave surface 32), andoutlet channel 16 transporting asolids flow 40 of a finely divided transport assisting solids 41 (e.g., sand, ground biomass, coal fines, petroleum coke fines, pulverized limestone, ground glass, small flexible polymer beads, crumb rubber, and the like or any combination thereof). Thetransport assisting solids 41 are solids that have been pulverized, ground, crushed, manufactured, formed and/or treated in some way so that each particle is defined by aparticle diameter 42. Theparticle diameter 42 may be defined by a maximum value for each particle or thetransport assisting solids 41 may be defined by a certain proportion being smaller than a maximum value. By further example, thetransport assisting solids 41 may all be smaller than approximately 30-50 Mesh (i.e., 0.599-0.297 µm). For example, thetransport assisting solids 41 may include material in which 60, 70, 80, or 90 percent of the particles are smaller than approximately 100 Mesh (i.e., 0.152 µm). The small diameter (relative to the size of the channel 33) particles illustrated inFIG. 2 represent the various particles and depict that theparticles 40 are capable of forming a tightly packed column within thepump 10 that is capable of sustaining the high pressure drop between the high pressure zone at theoutlet channel 16 and the low pressure zone at theinlet channel 14. -
FIG. 3 is a schematic of a simplified representation of an embodiment of asection 46 of the curvedsolids transport channel 33 between theinlet channel 14 and theoutlet channel 16 of the solids pump 10 shown inFIGS. 1 and2 , illustrating asolids flow 40 of relatively fineparticulate solids 41 moving through thepump 10. As illustrated, the solids flow 40 (e.g., low pressure fire particulate solids 41) moves through thechannel 33 in a downstream direction 26 (e.g., from left to right) under the influence of the oppositerotating disks 20 inside thepump 10. As discussed below, the fineparticulate solids 41 are relatively closely packed together to help block fluid flow, such as gas or liquid flow. For example, the fineparticulate solids 41 with tight packing can resist a gas flow 44 (e.g., high pressure gas flow 44) flowing in an upstream direction 27 (e.g., from right to left), from the high pressure zone at theoutlet channel 16 to the low pressure zone at theinlet channel 14. The finely groundsolids 40 have aparticle size 42 distribution that is conducive to forming tightly packed solids in thepump 10, such as in thechannel 33 and theoutlet channel 16. The distribution of theparticle size 42 may include a broad range of particle sizes in order to achieve tight packing, or theparticle size 42 in some embodiments may have a narrow size distribution. However, theparticle size 42 of thesolids 41 may be relatively small. In these cases, open space or voids between thesolids 41 is limited in size. Due to the small spaces between thesolids 40, thehigh pressure gas 44 has a difficult time flowing from right to left. That is,pathways 52 forgas flow 44 from theoutlet channel 16 to theinlet channel 14 are few and small. Therefore, a high pressure drop is sustained between theoutlet channel 16 and theinlet channel 14. -
FIG. 4 is a schematic of thesection 46 of the curvedsolids transport channel 33 filled with large solid particles 48 (e.g., coarse particulate solids), which may have anarrow particle size 50 distribution (i.e., relative to the tightly packedfine solids 41 inFIG. 3 ). A narrow size distribution means that for example, due to the limited range of particle sizes (there are no small particles to fill in the gaps), or the random and irregular shapes of the particles, the particles do a poor job of packing and the resulting poorly packed solids offer little resistance to gas flow fromoutlet channel 16 toinlet channel 14. Pathways (i.e., spaces, voids, or gaps 52) for gas flow are many and large. Consequently, it may be difficult to transport thesesolids 48 against a high pressure drop. In certain embodiments, it may be desirable to use coarseparticulate solids 48 in a high pressure downstream system. -
FIG. 5 is a schematic of thesection 46 of the curvedsolids transport channel 33 ofFIGS. 3 and 4 , illustrating transport of a solids mixture of the large solid particles 48 (e.g., ofFIG. 4 ) and the finely ground solids 41 (e.g., ofFIGS. 2 and3 ). The small, tightly-packingsolids 41 are able to fill all the spaces between thelarge solids particle 48. Therefore, thepathways 52 forgas flow 44 are few and small. As with the embodiment of thepump 10 shown inFIG. 3 , the tight packing of the solids flow 40 achieved by the fineparticulate solids 41, which also fill thegaps 52 associated with the coarseparticulate solids 48, enables thepump 10 to maintain a high pressure drop between theoutlet channel 16 and theinlet channel 14. Thus, both the small particles (e.g., transport assisting solids 41) and the large particles (e.g., solid feed 48) can be transported by thepump 10 against ahigh pressure gas 44. The assistingsolids 41 may be made from a broad range of suitable materials. For example, a solids packing device 64 (seeFIG. 6 ) may use an attrition resistant material that is different from thesolid feed 48 material. These materials are used in transport assisting solids recycle embodiments as explained in detail below. The assistingsolids 41 may also include the same material as thesolid feed 48. That is, a portion of thesolid feed 48 may be pulverized to obtain a particle size distribution that is more efficient at packing thesolids flow 40. The assistingsolids 41 may also be made from polymer or rubber balls or beads that are flexible, resilient and compressible and that can deform around and cushion the large solids (particularly fragile chunk solids) as they pass through the solids pump 10. The assistingsolids 41 may also be made from a material (e.g. fluxant, additive, reactant) that is a desired participant in the downstream processing of thechunk solids 48. Either all or just a portion of these types oftransport assisting solids 41 stay with thepressurized chunks 48 that are fed into the end user process. -
FIG. 6 shows a block flow diagram for one embodiment of a system that employs the concept illustrated inFIG. 5 .Solids 48 from a source ofoversize solids 54 pass through asolids sizing device 56, such as a grinder or crusher, in order to produce size-reducedsolids 48 which are sized small enough to pass through the solids pump 10. The source ofoversize solids 54 may be a hopper or bin that stores thesolids 48, or may be a conveyor that constantly conveys thesolids 48 to thesolids sizing device 56. The source ofoversize solids 54 may also have other structural components. If theoversized solids 48 are already small enough to pass through thepump 10, the size reduction step may be eliminated. The size-reducedsolids 48 are stored in a sizedchunk solids bin 58 for further use. Note that, in the descriptions that follow, the terms sized chunks, chunks and chunk solids refer to solids that are characterized by a narrow particle size distribution with relative little or no smaller size particles available to fill in thegaps 52 between the larger ones (e.g., thesolids 48 shown inFIG. 4 ). In parallel with theoversize solids 48 sizing and storage steps, solids 41 (e.g., relatively fine particulate solids 41) from a source oftransport assisting solids 60 are loaded into a transport assistingsolids bin 62 for further use. Thesesolids 41 are capable of forming a tightly packed column, because they include a wide range ofparticle sizes 42, including fine and very fine particles that are able to fill in essentially all of thegaps 52 between alllarger particles 48. Following the chunk solids and transport assisting solids storage steps,chunk solids 48 andtransport assisting solids 41 are combined or mixed in asolids packing device 64. Thesolids packing device 64 may be located immediately upstream of theinlet channel 14 and is configured to completely surround thesolid feed 48 with the finertransport assisting solids 41 so that all of thegaps 52 between thesolid feed 48 that would otherwise be left open are now filled withtransport assisting solids 41. The combination 66 (e.g., solids mixture 43) ofchunk 48 andtransport assisting solids 41 then enters the solids pump 10 that meters and pressurizes thecombination 66 into anend user process 68 such as a gasifier, a reactor, a furnace, a boiler, a combustor, a high pressure treating process, or any combination thereof. -
FIG. 7 is a schematic of an embodiment of thesolids packing device 64 ofFIG. 6 . Atop portion 70 of thedevice 64 includes two concentricsolids delivery nozzles center nozzle 72 introduces the sizedsolid feed 48 into a central portion of thesolids packing device 64, and theouter nozzle 74 introduces thetransport assisting solids 41 into thedevice 64 around the outside of thesolid feed 48. Both nozzles (i.e.,center nozzle 72 and outer nozzle 74) have inwardly tapered or convergingwalls external vibrators 76 disposed on an outer surface to improve flow of solids 40 (e.g.,solid feed 48 and assisting solids 41) into and through thedevice 64. Thecenter nozzle 72 may be either flush with or retracted from theexit orifice 75 of theouter nozzle 74. As illustrated, thecenter nozzle 72 is retracted (e.g., axially offset) from anexit orifice 75 of theouter nozzle 74. Amiddle portion 78 of thesolids packing device 64 includes a vibrating packing column that ensures that thesolid feed 48 and thetransport assisting solids 41 are well mixed and well packed (e.g., acolumn 77 ensures that all thegaps 52 between thesolid feed 48 are completely filled with the transport assisting solids 41). Both theexternal vibrator 76 and one or moreinternal vibrators 80 disposed within a flow path of thesolids 48 andtransport assisting solids 41 are provided to ensure that thorough mixing and packing of the twosolids device 64. Abottom portion 82 of thesolids packing device 64 includes alive wall column 81 that actively transports the packedsolids mixture 66 into theinlet channel 14 of the solids pump 10 attached immediately below anexit 84 of thedevice 64. Thelive wall column 81 of thebottom portion 82 has a rotatingchannel 83 with internal spiral flutes 86 that act as a screw conveyor that actively moves the mixed solids stream 66 (e.g., solids mixture 43) downwards through thechannel 83. The rotatingchannel 83 is driven by a gear, such as anexternal worm gear 87. - In certain applications of the equipment configuration of
FIG. 7 , thesolid feed 48 may include a material that is somewhat fragile.Fragile materials 48 may be damaged by the solids pump 10, because of the high compressive and frictional forces that develop within portions of thepump 10. In order to minimize damage to fragilesolid feed 48, thetransport assisting solids 41 may include small, flexible polymer or rubber beads. Thebeads 41 that are added to thedevice 64 include shapes and a particle size distribution that facilitates efficient packing with thesolid feed 48 being fed through thedevice 64. When thesolids packing device 64 mixes the flexible,compressible beads 41 with the large, fragilesolid feed 48, thesolid feed 48 are surrounded by thebeads 41 and all the gaps 52 (e.g., void spaces) in thecombination 66 are filled with thebeads 41. As the combination 66 (e.g., solids mixture 43) moves through the solids pump 10, the flexible,compressible beads 41 not only provide the tight packing to sustain a pressure drop across thepump 10, but thebeads 41 also cushion the fragilesolid feed 48, thereby reducing the possibility that thechuck solids 48 may be damaged during their passage through the solids pump 10. -
FIG. 8 is a schematic of an embodiment of an equipment configuration for the process embodiment shown inFIG. 6 . A source ofoversize solids 54, passes the solids 48 (e.g., coal, petroleum coke, limestone, ore, wood, biomass, carbon-containing waste materials or any combination thereof) through agrinder 56 that reduces the solids to chunks that can effectively pass through the solids pump 10 (e.g., without jamming). Thegrinder 56 may be any suitable grinder that produces solids with the desired particle size. Thegrinder 56 may also size a portion of theoversize solids 54 intotransport assisting solids 60. The solid feed 48 (e.g., coal) is then stored in a sized chunk solids bin orhopper 58. A source oftransport assisting solids 60, such as pulverized coal 41 (e.g., possibly prepared from the same source), is loaded into the transport assisting solids bin orhopper 62. The transport assisting solids bin orhopper 62 may be of any suitable construction that is compatible with thetransport assisting solids 41 which it stores for use within thesolids packing device 64. The bin orhopper 62 may also be a conveyor belt, tube, or pump that constantly conveys thesolids 41 to thesolids packing device 64. The source ofoversize solids 54 may also have other structural components. The bottoms of both the transport assistingsolids bin 62 and the sizedchunk solids bin 58 may be fitted with rotatingstar valves 88 or other similar devices that meter the twosolids solids packing device 64. The twostar valves 88 may be controlled by a controller so as to feed the assistingsolids 41 and thesolid feed 48 into thesolids packing device 64 at a ratio that achieves efficient packing. Thesolids packing device 64 mixes and packs the two solids (i.e.,solid feed 48, such as chunk coal, and assistingsolids 41, such as pulverized coal) together and then feeds thecombination 66 into theinlet channel 14 of the solids pump 10. The solids pump 10 simultaneously pressurizes and meters thecombination 66 of pulverized andchunk coal 43 into a downstream end user process 68 (e.g. a pressurized fluidized bed combustor, reactor, or gasifier). - In an alternative application of the equipment configuration of
FIG. 8 , other materials may be substituted for the pulverized coal that was used as the transport assisting solids in the first example. For example, limestone may be used as a sulfur sorbent in coal combustion applications, and the use of pulverized limestone as thetransport assisting solids 41 in the equipment configuration ofFIG. 8 provides a convenient way to co-feed coal and sulfur sorbent into a pressurized fluidized bed combustor, reactor, or gasifier. - In a further alternative application of the equipment configuration of
FIG. 8 , the source ofsolid feed 48 may be wood, wood waste or some other oversize biomass material; and thetransport assisting solids 41 may be sawdust or similar finely divided biomass from a biomass processing facility. In this biomass application, thesolids packing device 64 mixes and packs the sized wood orbiomass chunks 48 with the sawdust or finely dividedbiomass 41 and then feeds the combinedbiomass stream biomass stream 43 into the downstreamend user process 68, such as a fluidized bed biomass gasifier or a steam-biomass reformer. A biomass feeding process may significantly improve the efficiency and economics of many biomass conversion processes. Many state-of-the-art biomass conversion processes are currently limited to relatively low pressure operation, because of the difficulty of pressurizing biomass feedstocks, many of which are available in sizes and particle size distributions that do not pack well. As a consequence, most biomass conversion processes must compress the product bio-syngas downstream of the biomass reactor in order to obtain high enough pressure for further processing, such as converting the bio-syngas to biomass-derived liquid fuels and chemicals or combusting the bio-syngas in a combustion turbine to generate electrical power. By using the biomass feeding process ofFIG. 8 , the biomass reactor can be operated at pressure that is higher than the pressures used by all downstream processes and, therefore, the intermediate compressor can be eliminated. - Note that, in
FIG. 8 , one or more pieces of equipment may be added, substituted or subtracted within the scope of the embodiment in the block flow diagram ofFIG. 6 . For example, if theoversize solids 48 are already available at a size that are unlikely to jam in the solids pump 10, thegrinder 56 may be eliminated. Although the solids pump 10 is shown as discharging directly into theend user process 68, the solids pump 10 may discharge to a screw conveyor, a pneumatic conveying system, or another process or device that does the final feeding to theend user process 68. -
FIG. 9 illustrates an embodiment for delivering thecombination 66 ofsolid feed 48 and assistingsolids 41 to theend user process 68. InFIG. 9 , the transport assistingsolids bin 62, thesolids sizing device 56, the sizedchunk solids bin 58, thesolids packing device 64 and the solids pump 10 generally have the same features and functions as described in the block flow diagram ofFIG. 6 . Additionally, the embodiment ofFIG. 9 is configured for situations in which thetransport assisting solids 41 are not used by theend user process 68 along with the pressurized chunk solids. To avoid delivering the assistingsolids 41 to theend user process 68, asolids separating device 90 may be placed downstream of the solids pump 10 to separate thetransport assisting solids 41 from thesolid feed 48 before thesolid feed 48 is delivered to theend user process 68 by a pressurizedsolids delivery system 92. Thetransport assisting solids 41 that were separated by thesolids separating device 90 are recycled back to the front end of the process in a recycle loop that begins with a transport assistingsolids depressurizing device 94. After thetransport assisting solids 41 have been depressurized bydevice 94, thesolids 41 are sent through a transport assisting solids attritedfines removal 96 where at least some of the attritedfines 97 are removed in order to prevent very fine material from accumulating within the transport assisted solids recycle loop. The non-attrited fines fraction of thetransport assisting solids 41 is then moved via arecycle system 98 to a transport assisting solids recyclebin 100 that provides buffer storage in the recycle system. Recycledtransfer assisting solids 41 are mixed with fresh transfer assisting solids and stored in atransport assisting solids 41 mixing andstorage bin 102 upstream of thesolids packing device 64. Mixedtransport assisting solids 41 from the mixing andstorage bin 102 are metered into thesolids packing device 64 along with the sizedsolid feed 48 to complete the cycle. -
FIG. 10 illustrates a cross-section of an embodiment of thesolids separating device 90 that can be used for the solids separation step downstream of the solids pump 10. A first example 104 is a simple, pressurized vibratingscreen 106 withopenings 108 that are small enough to block thesolid feed 48 from passing through but large enough to allow thetransport assisting solids 41 to pass. The separatingdevice 90 may also include atapered collection portion 109 that aggregates thetransport assisting solids 41. Aggregation by the taperedcollection portion 109 of thetransport assisting solids 41 may reduce losses that would otherwise result from the fine particulates in thetransport assisting solids 41 floating away due to agitation. -
FIG. 11 illustrates a cross-section of an embodiment of thesolids separating device 90. Thesolids separating device 90 ofFIG. 11 is a rotatingcylindrical tumbler screen 110 inside acylindrical pressure housing 112 that collects the separatedtransport assisting solids 41. The packedsolids combination 66 from the discharge of the solids pump 10 is fed into therotating screen 110, which is oriented with a slight downward slope frominlet 113 tooutlet 114. As thescreen 110 rotates,internal baffles 115 tumble the solids (e.g., thecombination 66,solid feed 48, and/or assisting solids 41). Thetransport assisting solids 41 pass throughsmall holes 116 in thescreen 110, while the largersolid feed 48 are retained inside thescreen 110 and, after progressing along the length of the downwardly slopingrotating screen 110, leave the solids separation device viaexit 114 to theend user process 68. -
FIG. 12 illustrates a cross-section of an embodiment of thesolids separating device 90. Thesolids separating device 90 ofFIG. 12 includes a verticalrotating screw conveyor 118 inside atubular screen 120 fixed inside a pressurizedcylindrical barrel 122 that collects the separatedtransport assisting solids 41. The packedsolids combination 66 exits from the solids pumpoutlet channel 16 toward the angled inlet that intersects one side of the top of thetubular screen 120 and the solids (e.g., thecombination 66,solid feed 48, and/or assisting solids 41) are transported downwards by the rotation of thescrew 118. As thescrew 118 rotates, the finertransport assisting solids 41 pass through the small holes in the fixedtubular screen 120, collect in theouter barrel 122, and exit via anozzle 124 at the bottom. The largersolid feed 48 remains on thescrew 118 and exits the separating device at the bottom of thescrew 118. In certain embodiments, thesolids separating device 90 is reversed so that the combined, packedsolids combination 66 enters the bottom of thescrew 118 and flows upward. Thus, therotating screw 118 would discharge thelarge chunks 48 at the top, while the separatedtransport assisting solids 41 would still exit via thenozzle 124 at the bottom of thebarrel 122. AlthoughFIGS. 10, 11, and 12 illustrate three possible examples ofsolids separation devices 90, the disclosed systems and methods may use any othersolids separating devices 90 alone or in combination with any or all of thedevices 90 depicted inFIGS. 10, 11, and 12 . -
FIG. 13 illustrates an embodiment for the process shown inFIG. 9 . As in the first embodiment, asource 54 of oversizesolid feed 48, such as wood or oversize biomass, is reduced, if needed, to a size that will not get stuck in the solids pump 10. The sizedsolid feed 48 is stored in a sized chunk solids bin orhopper 58 with a rotatingstar valve 88 or similar device at the bottom that meters thesolid feed 48 into thesolids packing device 64. Mixedtransport assisting solids 41 from the transport assisting solids mixing andsolids bin 102 are also metered into thesolids packing device 64 via a rotatingstar valve 88 or similar device at the bottom of thatbin 102. The rotatingstar valves 88 are controlled in such a way as to meter the sizedsolid feed 48 and the assistingsolids 41 into thesolids packing device 64 in the correct mass flow ratio. - The
solids packing device 64 mixes and packs thesolid feed 48 with the assistingsolids 41 and feeds the combination 66 (e.g., solids mixture 43) to theinlet channel 14 of asolids pump 10. The solids pump 10 pressurizes the mixed and packedcombination 66 to the pressure used within theend user process 68. The illustrated embodiment inFIG. 13 may be used when theend user process 68 does not accept the assistingsolids 41 that were pressurized along with thesolid feed 48. Therefore, a separatingdevice 90, such as one or more of the embodiments shown inFIGS. 10-12 , is deployed downstream of the solids pump 10. - As illustrated in
FIG. 13 , the verticalrotating screw conveyor 118 may be used to separate the assistingsolids 41 from thesolid feed 48. Also as illustrated, the process of separation by the separatingdevice 90 may occur completely within the pressurized zone 120 (e.g., the section of the in which processes are at a higher pressure than the sections outside the pressurized zone 120). As thepressurized combination 66 from the solids pump 10 passes through the verticalrotating screw conveyor 118, the assistingsolids 41 pass through the screen and are collected in the outer barrel while thesolid feed 48 is delivered by the screw to the inlet of a second solids pump 10 which may perform the final metering of thesolid feed 48 into theend user process 68. In certain embodiments, the second solids pump 10 has a high pressure body, but it does little or no additional pressurization of thesolid feed 48. Therefore, the second solids pump 10 may be the same type of solids pump, or may be a different type of solids pump 10. The second solids pump 10 may also be configured as just a metering device. - The assisting
solids 41 which were separated from thesolid feed 48 enter a third solids pump 10 which operates in depressurization mode to reduce the pressure of the assistingsolids 41 back to atmospheric pressure or another low pressure. The third solids pump 10 may also be the same type as either the first or the second solids pump 10, or the third solids pump 10 may be different than either of the other solids pumps 10. The depressurized assistingsolids 41 are then screened in the transport assisting solids attritedfines removal unit 96 to remove the very finestattrited particles 97 of the assistingsolids 41. The overflow from the attritedfines removal unit 96 is transported via arecycle system 98 such as a conveyor belt, a screw conveyor or a pneumatic conveying system to an assisting solids recycle storage bin orhopper 100. Fresh assistingsolids 41 are also loaded into a fresh assisting solids storage bin orhopper 62. Both of these bins or hoppers (e.g., fresh assistingsolids storage bin 62 and assisting solids recycle storage bin 100) are fitted on the bottom with rotatingstar valves 88 or similar devices that meter the fresh assistingsolids 41 and therecycle assisting solids 41 into a transport assisting solids mixing and storage bin orhopper 102 via mixingcolumn 104. The assistingsolids mixing column 104 contains an open structure of internal baffles that mixes the two assistingsolids 41 streams at the ratio of mass flow rates controlled by thestar valves 88 as the two streams fall by gravity through the baffle structure within themixing column 104 and into the transport assisting solids mixing andstorage bin 102. - One or more of the illustrated pieces of equipment may be added, substituted, or subtracted within the scope of the embodiment shown in the block flow diagram of
FIG. 9 . For example, if theoversize solids 48 are already available at a size that is unlikely to jam in the solids pump 10, thegrinder 56 may be eliminated. Although the second solids pump 10 is shown as discharging directly into the downstreamend user process 68, thesecond pump 10 may alternatively discharge to a screw conveyor, a pneumatic conveying system, a chute or another process or device that does the final feeding to theend user process 68. In an alternative embodiment, the second solids pump may be replaced by a screw conveyor, a pneumatic conveying system, a chute or another device that does the final feeding directly from the discharge of thesolids separator 90 into theend user process 68. In certain embodiments, the vertical screw conveyorscreen separating device 118 may be replaced or supplemented with one of the othersolids separating devices 90, the third solids pump 10 may be replaced by a lock hopper system, and/or the attrited fines screen 96 and the transport assistingsolids mixing column 104 may be replaced by alternative devices that perform the same or similar functions. -
FIG. 13 may also be used to represent a possible equipment configuration for a third process embodiment that is also consistent with the block flow diagram shown inFIG. 9 . The first process embodiment, shown inFIG. 8 , may be a once-through system in which thetransport assisting solids 41 pass through the system just once and then are fed into the downstreamend user process 68 along with thesized chunk solids 48. Such a process may be useful when the transport assisting solids can be tolerated by the end user process or when they can be fashioned from a material that is a desired participant in the further processing of thesized chunk solids 48 in theend user process 68. The second process embodiment, shown inFIG. 11 , is a recycle system in which all of thetransport assisting solids 41 are separated from thesized chunk solids 48 downstream of the solids pump so that thetransport assisting solids 41 can be recycled to the front end of the system for reuse. Such a process may be useful if theend user process 68 cannot tolerate the presence of the finely divided transport assisting solids, if thetransport assisting solids 41 are expensive and must be conserved or if it is desirable to minimize the energy to produce the finely dividedtransport assisting solids 41. The third process embodiment, which may also be represented by the equipment inFIG. 13 , is a hybrid of the first and second embodiments. A difference is that the efficiency of thesolids separating device 90 downstream of the solids pump 10 is reduced so that some of thetransport assisting solids 41 are separated for recycle while the rest remain with the sized chunk solids and are fed into the downstreamend user process 68. Such a process may be useful when the transport assisting solids can be fashioned from a material that is a desired participant in the further processing of thesized chunk solids 48 in the end user process, but not in the quantity that is required to achieve the desired level of packing to sustain the pressure drop across the solids pump 10. An example might be a high pressure metals refining process in which a small amount of non-metallic fluxant is desirable. If the non-metallic fluxant is also a suitable material for use as thetransport assisting solids 41, the efficiency of thesolids separating device 90 can be tailored to allow just enough of it to pass through with thechunk solids 48 so that any fluxant used by the downstreamend user process 68 is sufficiently provided. - Technical effects of the disclosed embodiments include a solid feed pump that has a channel configured to move solids from a low pressure condition to a higher pressure condition, or from a high pressure condition to a low pressure condition. In order to smoothly and consistently maintain the pressure differential, the system also includes a solids packing device coupled to the solid feed pump. The solids packing device receives
chunk solids 48 with a narrow range of chunk sizes, and also receivestransport assisting particles 41 with a second range of sizes. The first range of sizes may be bigger than the second range of sizes, but the first range of sizes does not allow the chunk solids to pack tightly enough to maintain the pressure differential between the high pressure condition and the low pressure condition. An additional channel is configured to receive and mix thesolid feed 48 and thetransport assisting particles 41 to provide asolid feed 48/transport assisting particles 41 mixture with thetransport assisting particles 41 fillinginterspatial spaces 52 between thesolid feed 48. - This written description uses examples to disclose the invention, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
- Various aspects and embodiments of the present invention are defined by the following numbered clauses:
- 1. A system, comprising:
- a solids packing device comprising:
- a first channel configured to receive a solid feed with a first range of sizes;
- a second channel configured to receive transport assistance particles (TAP) with a second range of sizes, wherein the first range of sizes is different from the second range of sizes; and
- a third channel configured to receive and mix the solid feed and the TAP to provide a solid feed-TAP mixture with the TAP filling interspatial spaces between the solid feed; and
- a solid feed pump, comprising:
- a housing;
- a passage disposed within the housing;
- a solid feed inlet configured to receive the solid feed-TAP mixture from the third channel and provide the solid feed-TAP mixture to the passage; and
- a solid feed outlet coupled to the passage.
- a solids packing device comprising:
- 2. The system of clause 1, wherein a second portion of the second channel is circumferentially disposed about a first portion of the first channel.
- 3. The system of any preceding clause, wherein the solid feed-TAP mixture is configured to enter the solid feed inlet at a first pressure and to exit the solid feed outlet at a second pressure, the second pressure is higher than the first pressure, and the solid feed-TAP mixture is configured to block a flow of a gas between the solid feed outlet and the solid feed inlet to enable a pressure gradient across the passage between the solid feed inlet and the solid feed outlet.
- 4. The system of any preceding clause, wherein the solids packing device comprises a first vibrator disposed on an external surface of the solids packing device, a second vibrator disposed within the solids packing device in a flow path of the solid feed-TAP mixture, an external worm gear drive configured to rotate internal spiral flutes within the third channel, or any combination thereof, wherein the first or second vibrator is configured to facilitate packing of the solid feed and the TAP.
- 5. The system of any preceding clause, wherein the TAP comprise particles smaller than 30 Mesh.
- 6. The system of any preceding clause, wherein the TAP comprise
particles 60 percent of which are smaller than 100 Mesh. - 7. The system of any preceding clause, wherein the TAP comprises a first material, and the solid feed comprises a second material different from the first material.
- 8. The system of any preceding clause, wherein the solid feed comprise coal, petroleum coke, limestone, ore, wood, biomass, carbon-containing waste materials or any combination thereof.
- 9. The system of any preceding clause, wherein the TAP comprise sand, ground biomass, coal fines, petroleum coke fines, pulverized limestone, ground glass, small flexible polymer beads, crumb rubber, or any combination thereof.
- 10. The system of any preceding clause, wherein the solid feed comprise fragile solid feed and the TAP comprise compressible particles configured to absorb compressive forces within the curved passage to deform around and to cushion the fragile solid feed to minimize damage to the fragile solid feed from the compressive forces.
- 11. A system, comprising:
- a solids packing device comprising a first inlet and a second inlet;
- a solids source configured to provide solids to the first inlet, wherein the solids have a first range of sizes;
- an assisting solids source configured to provide assisting solids to the second inlet, wherein the assisting solids have a second range of sizes different from the first range of sizes; and
- a solids pump configured to receive the solids and the assisting solids from the solids packing device at a first pressure and deliver the solids and the assisting solids to a pressurized end user system at a second pressure.
- 12. The system of any preceding clause, wherein the assisting solids source is configured to add a fluxant, an additive, a reactant, or any combination thereof, for use in the pressurized end user system.
- 13. The system of any preceding clause, wherein the assisting solids comprise particles smaller than 30 Mesh.
- 14. The system of any preceding clause, comprising a grinder configured to grind a portion of the solids to create the assisting solids.
- 15. A system, comprising:
- a solids packing device comprising a first inlet and a second inlet;
- a first source configured to provide solids to the first inlet of the solids packing device;
- a second source configured to provide assisting solids to the second inlet of the solids packing device;
- a solids pump configured to receive a mixture of the solids and the assisting solids from the solids packing device; and
- a solids separating device configured to receive the pressurized mixture of the solids and the assisting solids from the solids pump, separate the solids from the assisting solids, and output the solids separate from the assisting solids.
- 16. The system of any preceding clause, comprising an attrited fines screen configured to remove attrited fines from the assisting solids.
- 17. The system of any preceding clause, comprising a recycle system configured to depressurize and transport the assisting solids to the second inlet of the solids packing device.
- 18. The system of any preceding clause, comprising a second solids pump configured to meter the solids downstream of the solids separating device.
- 19. The system of any preceding clause, wherein the solids comprise a narrow range in particle size distribution.
- 20. The system of any preceding clause, wherein the solids separating device comprises a screen, a screw, a vibrator, a rotary device, or any combination thereof.
Claims (15)
- A system, comprising:a solids packing device comprising:a first channel configured to receive a solid feed with a first range of sizes;a second channel configured to receive transport assistance particles (TAP) with a second range of sizes, wherein the first range of sizes is different from the second range of sizes; anda third channel configured to receive and mix the solid feed and the TAP to provide a solid feed-TAP mixture with the TAP filling interspatial spaces between the solid feed; anda solid feed pump, comprising:a housing;a passage disposed within the housing;a solid feed inlet configured to receive the solid feed-TAP mixture from the third channel and provide the solid feed-TAP mixture to the passage; anda solid feed outlet coupled to the passage.
- The system of claim 1, wherein a second portion of the second channel is circumferentially disposed about a first portion of the first channel.
- The system of claim 1 or claim 2, wherein the solid feed-TAP mixture is configured to enter the solid feed inlet at a first pressure and to exit the solid feed outlet at a second pressure, the second pressure is higher than the first pressure, and the solid feed-TAP mixture is configured to block a flow of a gas between the solid feed outlet and the solid feed inlet to enable a pressure gradient across the passage between the solid feed inlet and the solid feed outlet.
- The system of claim 2 or 3, wherein the solids packing device comprises a first vibrator disposed on an external surface of the solids packing device, a second vibrator disposed within the solids packing device in a flow path of the solid feed-TAP mixture, an external worm gear drive configured to rotate internal spiral flutes within the third channel, or any combination thereof, wherein the first or second vibrator is configured to facilitate packing of the solid feed and the TAP.
- The system of any of claims 1 to 4, wherein the TAP comprise particles smaller than 30 Mesh.
- The system of any of claims 1 to 5, wherein the TAP comprise particles 60 percent of which are smaller than 100 Mesh.
- The system of any of claims 1 to 6, wherein the TAP comprises a first material, and the solid feed comprises a second material different from the first material.
- The system of any of claims 1 to 7, wherein the solid feed comprise coal, petroleum coke, limestone, ore, wood, biomass, carbon-containing waste materials or any combination thereof.
- The system of any of claims 1 to 8, wherein the TAP comprise sand, ground biomass, coal fines, petroleum coke fines, pulverized limestone, ground glass, small flexible polymer beads, crumb rubber, or any combination thereof.
- The system of any of claims 1 to 9, wherein the solid feed comprise fragile solid feed and the TAP comprise compressible particles configured to absorb compressive forces within the curved passage to deform around and to cushion the fragile solid feed to minimize damage to the fragile solid feed from the compressive forces.
- A system, comprising:a solids packing device comprising a first inlet and a second inlet;a solids source configured to provide solids to the first inlet, wherein the solids have a first range of sizes;an assisting solids source configured to provide assisting solids to the second inlet, wherein the assisting solids have a second range of sizes different from the first range of sizes; anda solids pump configured to receive the solids and the assisting solids from the solids packing device at a first pressure and deliver the solids and the assisting solids to a pressurized end user system at a second pressure.
- The system of claim 11, wherein the assisting solids source is configured to add a fluxant, an additive, a reactant, or any combination thereof, for use in the pressurized end user system.
- A system, comprising:a solids packing device comprising a first inlet and a second inlet;a first source configured to provide solids to the first inlet of the solids packing device;a second source configured to provide assisting solids to the second inlet of the solids packing device;a solids pump configured to receive a mixture of the solids and the assisting solids from the solids packing device; anda solids separating device configured to receive the pressurized mixture of the solids and the assisting solids from the solids pump, separate the solids from the assisting solids, and output the solids separate from the assisting solids.
- The system of claim 13, comprising an attrited fines screen configured to remove attrited fines from the assisting solids.
- The system of claim 13 or 14, comprising a recycle system configured to depressurize and transport the assisting solids to the second inlet of the solids packing device.
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US14/106,630 US9604182B2 (en) | 2013-12-13 | 2013-12-13 | System for transporting solids with improved solids packing |
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- 2014-12-09 KR KR1020140175619A patent/KR102229076B1/en active IP Right Grant
- 2014-12-11 EP EP14197289.3A patent/EP2884179B1/en not_active Not-in-force
- 2014-12-12 CN CN201410760426.7A patent/CN104709715B/en not_active Expired - Fee Related
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CN107090310B (en) * | 2017-02-09 | 2023-08-04 | 北京四维天拓技术有限公司 | Ladder gasification chamber |
Also Published As
Publication number | Publication date |
---|---|
KR20150069525A (en) | 2015-06-23 |
AU2014268286B2 (en) | 2019-01-17 |
EP2884179B1 (en) | 2017-02-22 |
AU2014268286A1 (en) | 2015-07-02 |
CN104709715B (en) | 2019-05-07 |
US20150165394A1 (en) | 2015-06-18 |
US9604182B2 (en) | 2017-03-28 |
CN104709715A (en) | 2015-06-17 |
KR102229076B1 (en) | 2021-03-16 |
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